Dirt separator

ABSTRACT

A dirt separator that includes an inlet; an outer wall defining a first dirt collection chamber of a first separation stage; an inner wall defining a second dirt collection chamber of a second separation stage; at least one rib extending from the inner wall into the second collection chamber; and a closure member hingedly connected to the dirt separator and movable between a closed position for sealing open ends of both the first and second dirt collection chambers and an open position for escape of dirt from the open ends. The closure member comprises a seal for sealing against the inner wall when the closure member is in the closed position, and the at least one rib has an end edge that is inclined such that the seal rides along the end edge and onto the inner wall as the closure member is closed.

REFERENCE TO RELATED APPLICATIONS

This application claims the priority of United Kingdom Application No. 1722301.7, filed Dec. 30, 2017, the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a dirt separator, in particular a dirt separator for a vacuum cleaner.

BACKGROUND OF THE INVENTION

Improvements to vacuum cleaners are always being sought, especially improvements that allow the vacuum cleaner to be made smaller and lighter. This is particularly important with handheld vacuums. It is desirable to make vacuum cleaners smaller and lighter, but without it negatively affecting important factors such as performance and ease of use for a user. Adequate sealing of components within the vacuum cleaner is vital for achieving the best possible performance. And in addition, it is apparent that users of vacuum cleaners prefer the process for emptying the dirt and dust collected by the vacuum cleaner to be as clean and hygienic as possible, preferably in a way that the vacuum cleaner can be emptied into a bin without the user needing to touch any dirty areas.

SUMMARY OF THE INVENTION

A first aspect of the present invention provides a dirt separator for a vacuum cleaner, the dirt separator comprising: an inlet for receiving a dirt-laden airflow; an outer wall defining a first dirt collection chamber for collecting dust and dirt separated from the airflow in a first separation stage; an inner wall defining a second dirt collection chamber for collecting dust and dirt separated from the airflow in a second separation stage, the second dirt collection chamber being positioned within the first collection chamber; at least one rib extending from the inner wall into the second collection chamber; and a closure member hingedly connected to the dirt separator so as to be movable between a closed position in which the closure member seals open ends of both the first and second dirt collection chambers and an open position in which dust and dirt can escape from the open ends of the first and second dirt collection chambers. The closure member comprises a seal for sealing against the inner wall when the closure member is in the closed position, and the at least one rib has an end edge that is inclined such that the seal rides along the end edge and onto the inner wall as the closure member is closed.

As a result, the seal for sealing the inner wall to the closure member can be positioned on the closure member, while ensuring a satisfactory seal is made between the closure member and the inner wall. The angled edge on the at least one rib ensures that the seal makes correct contact around the inner wall, and does not become trapped or damaged as the closure member is closed. By having the seal positioned on the closure member, it is possible for the inner wall to maintain a constant outer diameter through the first dirt collection chamber. This assists dirt ejection from the first dirt collection chamber. For instance, if the seal were required to be fixed to the inner wall, then there would be a corresponding constriction in the first dirt collection chamber, which could result in dirt becoming trapped between the inner wall and the outer wall at the constriction point, and which would need user intervention to be removed.

The seal may be a cuff seal. A cuff seal will seal along a portion of the inner wall, rather than just with an end of the wall, and as a result the cuff seal can ensure an adequate seal is made with the inner wall.

The seal may be formed of a resilient material and may have an inner diameter that is smaller than an outer diameter of the inner wall, such that it stretches as the closure member is closed and it rides along the at least one rib onto the inner wall. This goes even further to ensure an adequate seal is made with the inner wall.

The seal may have an inner diameter that is substantially the same as an outer diameter of the inner wall. As a result, an adequate seal can be achieved with the additional benefit that closing and opening of the closure member is not hindered by an unnecessarily tight seal between the seal and the inner wall.

The inlet may comprise an inlet duct that extends through the second dirt collection chamber. The at least one rib may extend between the inlet duct and the inner wall. As a result the at least one rib is supported by both in the inlet duct and the inner wall, and is structurally more secure.

The inlet duct may extend through a hole in the closure member.

The at least one rib may separate the second dirt collection chamber into a plurality of sub-chambers. The sub-chambers provide areas for the fine dust to settle, and helps to avoid any possible re-entrainment of the fine dust into airflow within the second separation stage.

The at least one rib may extend from a point on the inner wall that is closest to a hinge point for the closure member. Due to the hinged pivoting movement of the closure member as it closes, the seal at the point closest to the hinge is most likely to become trapped between the closure member and the inner wall. Therefore having the at least one rib positioned at this point, the risk of the seal becoming trapped is significantly reduced.

There may be a plurality of ribs extending from the inner wall into the second collection chamber. A larger portion of the seal would therefore be able to ride along the plurality of ribs, thus reducing the risk of any part of the seal becoming trapped between the inner wall and the closure member.

The plurality of ribs may extend parallel to each other, and extend from the inner wall in a direction away from a hinge point for the closure member. The first and second dirt collection chambers may be annular. The dirt separator may be a cyclonic separator.

The present invention further provides a vacuum cleaner comprising a dirt separator as described in any one of the preceding statements.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the present invention may be more readily understood, embodiments of the invention will now be described, by way of example, with reference to the following accompanying drawings, in which:

FIG. 1 is a vacuum cleaner;

FIGS. 2A and 2B show the vacuum cleaner of FIG. 1 at different stages during a dirt emptying procedure;

FIG. 3 shows the vacuum cleaner of FIG. 1 during a procedure to close the dirt separator;

FIG. 4 shows a perspective view of the inside of a dirt separator; and

FIGS. 5A-D show a schematic representation of a cuff seal positioning itself around an inner wall.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a vacuum cleaner 1 having a dirt separator 2, a main body 3, a handle 4, a power source in the form of battery pack 5, and a suction inlet 6. At the rear of the vacuum cleaner 1, attached to the main body 3, is a filter assembly 7. The vacuum cleaner is operated by the trigger 8 in the handle 4.

The dirt separator 2 has a first separation stage and a second separation stage. The first separation stage comprises a cylindrical outer wall 21 which defines a first dirt collection chamber 20, sometimes referred to as a bin. A cylindrical inner wall 25 defines a second dirt collection chamber which is positioned inside the first dirt collection chamber. A closure member in the form of a bin lid 9 is hingedly attached to the outer wall 21 of the dirt separator 2 at hinge 10. The bin lid is pivotable about the hinge 10 between an open position in which dust and dirt can escape from open ends of the first and second dirt collection chambers, and a closed position in which the closure member seals open ends of both the first and second dirt collection chambers. The bin lid 9 comprises a cuff seal 30 which seals against the outside of the inner wall 25 to ensure that the first and second dirt collection chambers are separated. A central portion of the bin lid 9 comprises a hole or opening through which the suction inlet 6 protrudes.

Inside the first dirt collection chamber 20 is a shroud 22 comprising a cylindrical screen 23 and a shroud skirt 24. During operation, air is drawn into the vacuum cleaner 1 through the suction inlet 6 by a fan motor housed within the main body 3. The dirt-laden air enters the dirt separator 2 through an inlet (not shown) in the side wall of the shroud 22 which is joined to the suction inlet 6 by an inlet duct extending between the two, the inlet duct extending through the inside of the second dirt collection chamber. The air spirals around the inside of the first dirt collection chamber 20, and centrifugal forces separate out larger dirt particles from the airflow which settle the in the first dirt collection chamber 20. The shroud screen 23 comprises a plurality of perforations through which air exits the first separation stage.

The second separation stage comprises a plurality of cyclone bodies 26. The air passes through the cyclone bodies 26 which separate any remaining dirt and dust from the airflow. The dirt and dust separated in the second separation stage collects in the second dirt collection chamber which is defined by the inner wall 25. Cleaned air exits the cyclones 26, passes through the fan motor in the main housing 3 and then is expelled from the vacuum cleaner 1 through the filter assembly 7.

In order to empty the dirt collection chambers, the bin lid 9 can be opened. FIGS. 2A, and 2B show the vacuum cleaner 1 at different stages during a dirt emptying procedure. The dirt separator 2 is provided with a bin opening actuator 27 which is fixed to the outer wall 21. When the bin opening actuator 27 is pushed in a direction away from the handle 4, as represented by arrow A in FIG. 2A, this causes the outer wall 21 and the bin lid 9 of the first dirt collection chamber to slide along the runner portion 28 of the vacuum cleaner 1 in the same direction. The shroud 22, inner wall 25, and the suction inlet 6 remain stationary as they are fixed to the main body 3. The seal 30 is separated from the inner wall 25, revealing the open end of the second dirt collection chamber 32. Once the outer wall 21 has reached a certain point in the direction away from the handle, as shown in FIG. 2B, it stops and a catch 33 holding the bin lid 9 closed is released. The bin lid 9 is hinged and a biasing member in the hinge 10 biases the bin lid 9 into an open position. Accordingly, as soon as the catch 33 is released, the bin lid 9 pivots around the hinge 10, and swings open as represented by arrow B. Dirt collected within the first and second dirt collection chambers 20, 32 can now be ejected from the dirt separator 2.

Closing the dirt separator 2 comprises sliding the outer wall 21 back to the original position as represented by arrow C in FIG. 3, and pivoting the bin lid 9 into a closed position, as shown by arrow D, until the catch 33 engages again to hold the bin lid 9 in the closed position.

During the closing operation, the cuff seal 30 must re-position itself around the outside of the inner wall 25. It is important for the seal 30 to be positioned correctly otherwise air would be able to pass between the first dirt collection chamber 20 and the second dirt collection chamber 32, and the vacuum cleaner 1 may stop functioning correctly. In order to ensure the seal 30 positions itself correctly as the bin lid 9 is closed, a number of ribs 34 extend between the inner wall 25 and the inlet duct.

FIG. 4 shows a perspective view of the inside of the dirt separator 2, with the bin lid 9 removed. This view shows the inlet 6, the inlet duct 36, the first and second dirt collection chambers 20, 32, and the ribs 34 more clearly. The end edges 35 of the ribs 34 are inclined from the inlet duct 36 towards the inner wall 25. The inclined edges 35 provide a surface against which the cuff seal 30 can slide in order to position itself on the outside of the inner wall 25 correctly, and to prevent it getting trapped between the bin lid 9 and the end of the inner wall 25. In the embodiment shown in FIGS. 3 and 4, the ribs 34 are not evenly positioned around the entire opening of the second dirt collection chamber 32, but are instead grouped in an area closest to the hinge point of the bin lid 9. This is the area at which the cuff seal 30 is most likely to be trapped and damaged compared to the opposite side of the second dirt collection chamber 32 on the other side of the inlet duct 36, and so it is beneficial to concentrate the ribs 34 in this area. However, in alternative embodiments, it may be preferable to evenly distribute the ribs 34 around the whole opening of the second dirt collection chamber 32.

FIGS. 5A, 5B, 5C and 5D show a schematic representation of a cuff seal 30 positioning itself around the inner wall 25. An inlet duct 36 extends beyond the inner wall 25, and ribs 34 extend between the inlet duct 36 and the inner wall 25. The annular cavity bounded by the inlet duct 36 and the inner wall 25 is the second dirt collection chamber 32. The ribs 34 extend beyond the inner wall 25, and the end edges 35 of the ribs 34 are inclined. The seal 30 has an inner diameter that is slightly smaller than the outer diameter of the inner wall 25. The seal 30 is made of a resilient material, such as rubber, and so is able to stretch to accommodate the larger diameter of the inner wall 25. This ensures that there is a tight fit between the seal 30 and the inner wall 25.

The seal 30 is moved towards the inner wall 25 in the direction of arrows E, until the seal makes contact with the ribs 34, as shown in FIG. 5B. When the seal 30 contacts the end edges 35 of the ribs 34, it is deflected outwards by them as shown by arrows F. The seal 30 starts to stretch such that it rides along the inclined edges 35 until it starts to position itself around the inner wall 25 as shown by arrows G in FIG. 5C, until it reaches its final position around the outer wall 25 as shown in FIG. 5D.

In the embodiment shown in FIGS. 5A-D, the seal 30 has an inner diameter that is slightly smaller than the outer diameter of the inner wall 25. However, alternatively an adequate seal may still be achieved if the inner diameter of the seal is substantially the same as the outer diameter of the inner wall 25. Furthermore, the ribs 34 are shown extending only partially inside the second dirt collection chamber 32. However, in an alternative arrangement, the ribs 34 could extend further into the second dirt collection chamber, and could, for example separate the second dirt collection chamber 32 into a number of smaller sub-chambers.

Whilst particular embodiments have thus far been described, it will be understood that various modifications may be made without departing from the scope of the invention as defined by the claims.

For example, the dirt separator 2 shown and described herein is a cyclonic separator, but it could be any dirt separator having two separation stages and separate dirt collection chambers, and the separation method is not necessarily limited to cyclonic. In addition, the embodiments described herein have the ribs 34 extending between an inlet duct 36 and the inner wall 25 However, if there is no inlet duct available, the ribs may just extend inwards from the inner wall into the second dirt chamber, and may not be supported at the other end, or could be supported by a different component of the vacuum cleaner instead of an inlet duct. 

1. A dirt separator for a vacuum cleaner, the dirt separator comprising: an inlet for receiving a dirt-laden airflow; an outer wall defining a first dirt collection chamber for collecting dust and dirt separated from the airflow in a first separation stage; an inner wall defining a second dirt collection chamber for collecting dust and dirt separated from the airflow in a second separation stage, the second dirt collection chamber being positioned within the first collection chamber; at least one rib extending from the inner wall into the second collection chamber; and a closure member hingedly connected to the dirt separator so as to be movable between a closed position in which the closure member seals open ends of both the first and second dirt collection chambers and an open position in which dust and dirt can escape from the open ends of the first and second dirt collection chambers, wherein the closure member comprises a seal for sealing against the inner wall when the closure member is in the closed position, and the at least one rib has an end edge that is inclined such that the seal rides along the end edge and onto the inner wall as the closure member is closed.
 2. The dirt separator of claim 1, wherein the seal is a cuff seal.
 3. The dirt separator of claim 2, wherein the seal is formed of a resilient material and has an inner diameter that is smaller than an outer diameter of the inner wall, such that the seal stretches as the closure member is closed and the seal rides along the at least one rib onto the inner wall.
 4. The dirt separator of claim 2, wherein the seal has an inner diameter that is the same as an outer diameter of the inner wall.
 5. The dirt separator of claim 1, wherein the inlet comprises an inlet duct that extends through the second dirt collection chamber.
 6. The dirt separator of claim 5, wherein the at least one rib extends between the inlet duct and the inner wall.
 7. The dirt separator of claim 4, wherein the inlet duct extends through a hole in the closure member.
 8. The dirt separator of claim 1, wherein the at least one rib separates the second dirt collection chamber into a plurality of sub-chambers.
 9. The dirt separator of claim 1, wherein the at least one rib extends from a point on the inner wall that is closest to a hinge point for the closure member.
 10. The dirt separator of claim 1, wherein a plurality of ribs extend from the inner wall into the second collection chamber.
 11. The dirt separator of claim 10, wherein the plurality of ribs extend parallel to each other, and extend from the inner wall in a direction away from a hinge point for the closure member.
 12. The dirt separator of claim 1, wherein the first and second dirt collection chambers are annular.
 13. The dirt separator of claim 1, wherein the dirt separator is a cyclonic separator.
 14. A vacuum cleaner comprising a dirt separator that comprises: an inlet for receiving a dirt-laden airflow; an outer wall defining a first dirt collection chamber for collecting dust and dirt separated from the airflow in a first separation stage; an inner wall defining a second dirt collection chamber for collecting dust and dirt separated from the airflow in a second separation stage, the second dirt collection chamber being positioned within the first collection chamber; at least one rib extending from the inner wall into the second collection chamber; and a closure member hingedly connected to the dirt separator so as to be movable between a closed position in which the closure member seals open ends of both the first and second dirt collection chambers and an open position in which dust and dirt can escape from the open ends of the first and second dirt collection chambers, wherein the closure member comprises a seal for sealing against the inner wall when the closure member is in the closed position, and the at least one rib has an end edge that is inclined such that the seal rides along the end edge and onto the inner wall as the closure member is closed. 